Welder

ABSTRACT

The system provides both a portable and appliance welding system. It can be use in the shop and field. In either location it can be plugged in or battery driven. When plugged in it can weld while charging simultaneously offering 100% duty cycle for heavy shop use, and a full range of metal thicknesses can be welded with ease. The system is implemented with a solid state high energy circuit; unrestricted and unfiltered, offering a wide spectrum of pure analog power. The systems is compact for maximum portability and use in remote field operations, yet can handle deep welds in a variety of metal compositions, conditions, environments, and sizes. The system uses a proven and robust storage medium of direct electric potential energy that is supplied by industrial batteries.

This patent application claims priority to U.S. Provisional PatentApplication No. 61/160,210 filed on Mar. 13, 2009 which is incorporatedby reference herein in its entirety.

BACKGROUND OF THE SYSTEM

There are certain circumstances where welding operations must be done inthe field instead of in a workplace (at the bench). For example, whenheavy machinery breaks during use, it is often infeasible oruneconomical to move the machinery to a workplace where it can berepaired. Instead, the machinery must be repaired in situ.

Prior art systems for providing field welding have a number ofdisadvantages in performance, economics, timeliness, reliability, noise,safety, repairability, complexity, and ease of use. One prior artattempt for field welding is the use of a generator welder or a heavyand cumbersome portable welder. A traditional portable welder may bepowered in a number of ways. One method requires such a portable welderto be dependently plugged in to a utility supplied power grid via a verylong drop cord. This severely limits the applicability of such a systemto where utility power is available because the range of a drop cord islimited. In addition, a drop cord can short out, creating a fire hazard.In many cases, there is no power grid resource available in the locationwhere use is required.

Prior art portable Gen-Set systems start by implementing 60 cyclesalternating current (AC) electrical power, typically at 240 volts,single or three phase AC; designed on a derivation of integratedcircuits (IC's) configured to regulate welder output. Heating andvibration are harmful to typical circuit elements and IC's; compoundedwhen driven by an internal combustion engine as entropy increasesrapidly inside such a system as heat exponentially increases at highercurrent levels. Typical portable welders deliver a narrow spectrum oflow quality output power and a poor usable duty cycle at the expense ofwaste heat. Most Gen-Set portable welder power sources are large andheavy and will overheat while delivering, noisy noxious exhaust gases, aderated duty cycle, high consumables such as MIG/TIG components andgases. The result is a cumbersome, unpredictable, and unreliable welderoutput of derated performance, all at a very high cost.

BRIEF SUMMARY OF THE SYSTEM

The system provides both a portable and appliance welding system. It canbe use in the shop and field. In either location it can be plugged in orbattery driven. When plugged in it can weld while chargingsimultaneously offering 100% duty cycle for heavy shop use, and a fullrange of metal thicknesses can be welded with ease. The system isimplemented with a solid state high energy circuit; unrestricted andunfiltered, offering a wide spectrum of pure analog power. The systemsis compact for maximum portability and use in remote field operations,yet can handle deep welds in a variety of metal compositions,conditions, environments, and sizes. The system uses a proven and robuststorage medium of direct electric potential energy that is supplied byindustrial batteries.

Other prior art approaches to welder designs include modifiedtransformers or even automotive alternators or generators powered byengines to motivate them. Other designs may include complex integratedcircuits using mosfet, triac, thyristor and inverter current controltechnologies, all at increased circuit complexity and a higher initialcost. Disadvantages of such systems include a propensity to failure inharsh extremes and systems that are unrepairable remotely, and requiredealer servicing for costly repairs. Existing systems designed with ICcomponents obtusely pieced together with an alternator motivated by aninternal combustion engine is an uneconomical and unnecessarily complexattempt to provide an ideal welding power source for an end user. Suchdesigns are failure prone when impacted by harsh weather or coupled tocombustion processes as typical designs overheat and output performancedecays. Further, such prior art welders require special permits from theUnited States Forest Service (USFS) as they are notorious for catchingfire or setting off forest fires. Under dynamic loads, the internalelectromagnetic and thermal properties within a typical prior artwelder's power source components can change undesirably out in thefield. The rapid charging and discharging from shorting out a weldingelectrode is a very heavy electrical load requirement. Further, typicalcircuit designs are not ideal under such loads as they are susceptibleto reactance/inductive/resistive (hysteresis) heat losses; resulting ina poor efficiency and poor power factor. For critical industrialproblems this power factor must be rectified externally by large andexpensive capacitor banks to achieve efficient unity. A balanced powerfactor is when capacitive reactance should equal inductive reactance.Otherwise, valuable energy is lost to internal hysteresis and as entropyincreases, expressed as inductive heat loss.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of one embodiment of the system.

FIG. 2 is a flow diagram illustrating the operation of the system.

DETAILED DESCRIPTION OF THE SYSTEM

The self contained welding device serves both as a portable and shopappliance welding system plus it can operate as an auxiliary power unit(APU). In either the field or shop environment the system can be pluggedin or just driven by its silent and scalable power cell battery bankuntil requiring recharge. An embodiment of the system uses industrialgrade batteries that are upgradable as future power storage innovationsare developed. The device is recharged by connection to common poweroutlet at only 115 volts AC/15 amps rated overnight. This improves overprior art systems that require 240 volt/50 amp outlets.

The system can also be recharged by a vehicle electrical system. This isaccomplished by inserting an optional adapter to power electrodestinger, converting over to a common battery clamp. This clamp can thenbe coupled directly to any support vehicle +12 volt battery terminal andthe remaining large clamp to frame ground The user then plugs theopposite end into device's first output stage. For heavy equipment ormilitary vehicles/vessels with electrical systems operating at +24volts, the same procedure is followed but connection is made into thedevice's second stage output. For Aircraft or any vessel at +36 volts orhigher use the device's third stage.

In addition to being chargeable from a vehicle, the device may itself beused to jump start a vehicle. When fully or even partially charged thesystem provides the opportunity to jump start or move any dead vehicleor vessel. For simultaneous charging of the device during operation, thedevice is coupled to a vehicle or power supply, the charger bank plug incord is coupled to its inboard AC power inverter, which in turn willeffectively charge up all the batteries quickly within the device.Charge is pulled off a vehicle's running alternator and inboard batterycombination, thereby making good use of available resources. In additionto welding, the device includes an outlet for coupling power tools viaits inboard power inverter while charging simultaneously as desired.

Offering 100% effectiveness expressed as real work, a high performanceduty cycle capable of extreme duty welding repairs, tool power and jumpstarter APU. A full range of metal thickness's can be welded with easeenabled by its proprietary power source, a safer high energy soft startlow voltage output.

The device quietly conducts and generates resonant high energyhyper-phase electromagnetic waveforms within the weldments metallurgy byuse of feedback through its feedback receiver. At the center of atoroidal array, easily accessible at the top of the device, there is apolymer cylindrical hollow chamber opening which may be loaded with amaterial sample. The chamber is then closed. The system then applieselectromagnetic energy to the sample which causes field effects thatrepresent properties of the sample. The electromagneticpermeability/reluctance and structural properties scan receives andestablishes needed metallurgical information which gets combined andtranslated then superimposed and communicated back as a signal conductedthrough the electrode of the device. The integrated plasma energy isexpressed into the molten weld puddle. The intelligent hyper-phaseplasma energy positively influences and overcomes weldment jointdisruptions. This enhances a weld's ultimate strength, flexibility,durability and overall performance. It is a function of a sample'sintegration scan versus the weldment's permeability/reluctance/fluxdensity. As properties are stimulated and information is received andabsorbed back into the circuit, superimposed wave reinforcement occurs.The translated intrinsic metallic energy is directly communicated backto the weldment, in a feedback loop where it is conducted andorchestrated by end user by the proprietary devive electrodes whichbecome one with the newly welded joint. The device's own stored energyis conducted back to the system, a feedback scan in the system receivesand generates information, an energetic expression of hyper-phasewaveforms are established by overall feedback reactions. Simplytranslated, information is transmitted out, received, translated bysuperposition, then communicated back to the weldment as conductedthrough the electrode as plasma expressed has a uniform magnetic fluxaction. The information rides upon the energetic plasma's carrier wavesas conducted by electrode as it fuses together with the weldment'smolten puddle and joint.

This circuit design, methodology and process; allows one to conduct mostefficiently intense high energy welds remotely out in the field. Theplasma impulses react and radiate Excimer like radiation blasting awayimpurities while reconstructing metal at intrinsic scanned feedbackfrequencies to subatomic wavelengths.

The device orchestrates a wide spectrum of intrinsic to metallicelectrodynamic pulsating power, its energy transformation conducts apowerful deep cleaning action to the weldment. Further, the outputenables the welding of irregular or contaminated or irregular joints andcompensates for any magnetic field disruptions, as a scanned samplesproperties command, offering a tight molten puddle and a high clingforce. This is ideal for extreme out of position welding or in harshweather.

The device's output offers a gentle but pulsating soft start or impulse,so that the electrode doesn't vaporize material away or get frozen tothe weldment. Later, higher energy impulses enables the electrode tooperate while being plunged deeply to the core of the joint and weld itfrom the inside out. Stably and deeply under pressure the hyper-phaseplasma arc thrusts and works under the molten puddle. The operationpowers through tough compositions and conditions in sensitive or severeenvironments, only emitting the same electrode by-products. Whenfinished the flux usually just lifts up and is most easily removed by asimple flick, tie in welds are easily stackable. This scalable devicestarts and works off of stored potential electrical energy. It utilizesa proven and robust storage medium able to withstand extremes, startingoff stored scalable amounts of electric potential energy. All that isrequired are industrial batteries or any charge storage device can beutilized, even a fuel cell or hybrid capacitors. Innovative industrialpower cells or batteries are used in one embodiment, which may haveMilitary spec ratings, depending on build requirements.

The system provides a way of harnessing, conducting, and orchestratingvery high potential electric energy into intrinsic kinetic standingenergy waves; generating an intense welding plasma, quietly, emissionsfree, and safely. Unimpeded analog energy of wide spectrum resonanceoccurs within, generating an intrinsic metal welding plasma.

The system's output power is not derived from any power regulated,digitally tuned, or filtered integrated circuits. Instead, the devicesoutput power is derived by a unique robust combination of a tunedresonant conductive power harness; tuned cables and electrode to metalinterface, directly connected to a power supply conducting unrestrainedpower, at the nearest unity power factor possible. Unique powerpulsations are conducted directly to the metal by proven: cableconnectors, harness, cables and electrode.

A self powered appliance; Consists of innovative industrial batteries,chargers, a tuned heavy gauge wired power harness containing aspecialized feedback device, an feedback receiver housed within arecyclable shock absorbing, non conductive, non corrosive advancedpolymer enclosure. Potential energy is stored within batteries thentranslated and transformed via high energy circuits design. Theelectrode at joint spark gap conducts and orchestrates enhancing energy.The plasma consists of a wide spectrum of high frequency electromagneticpulsed energy, hyper-phased, excited by design for reception ofresonance phenomenon. Electron charges are driven by the device then theweldment's metallurgy, self perpetuating, biasing and translatingmetallic intrinsic electromagnetic hyper-phase standing waves asintelligent energy. The device senses and receives then stores themetallic crystalline structures signatures.

The device initially charges up and drives its high energy circuitharness containing the proprietary feedback receiver which can be loadedwith a desired sample to react and bias the circuit into more desiredcoded information, expressed as an effective energetic response.

The energy is best conducted in one embodiment by the proprietarycompounds found in Thunder-Bolt-Rods having extremely low hydrogen andimpurities content. As the weldment circuit becomes biased it in turnbegins to resonate deeply and intrinsically in response to theweldment's metallurgies transforming energy into ideal energetic weldingrequirements. Corresponding to total systems and samplespermeability/reluctance and properties stimulated; in order to determineand establish natural frequencies and amplify a unison from within, allaccording to superposition phenomenon. Energizing and reacting viafeedback the reception converts stored electrical energy into anintelligent welding plasma energy. Completing the circuit generates anintensely effective welding plasma, simply, quietly, emissions free andsafely.

Generated in a tight zone is an intense arc of hyper-phase plasma energyfully tuned into the weldment. This tuned plasma drives intrinsichomogeneous inductive mixing of metals as eddy currents form deep withinthe weld puddle within joint of weldment, compressing out andincinerating impurities, as augmented by device expressed as weldingplasma. The plasma impulses react and radiate Excimer like radiationblasting away impurities while reconstructing metal at intrinsic scannedfeedback frequencies to subatomic wavelengths.

The welder system's output power is not subject to any power grid acalternated or generated power. It is not regulated or filtered power orpower from integrated control circuits. Instead, the device's outputpower starts off a robust combination of charged up electrical potentialenergy storage devices, IE: power cells, fuel cells, batteries or thelike. Further its feedback loop will condition the power cell withinbatteries and effectively remove any sulphide crystal formations orbridge shorts, boosting longevity from its regenerative charging action.Potential energy gets transformed by a tuned resonant conductive powerharness reacting with the feedback receiver as loaded with a desirablesample, tuned cables, Thunder-Bolt electrodes and the joint spark gapinteracts with the weldment itself. Conducting and orchestratingunrestrained smart power, at the nearest unity power factor possible;unique and intrinsically tuned impulse power pulsations are generated,smart information gathers and gets communicated then conducted backthrough the electrode to the weldments affected areas: disrupted joint,metallic structures, air/spark gap. The devices output overcomes thesedisruptions as biased by metallurgies, device performance is enhanced byfeedback of samples scan.

An embodiment of the system; Is illustrated in FIG. 1. The device'spower cells or batteries are hooked up in series and have an output tapor stage emanating from each positive terminal. In the embodiment allthat is needed is one negative ground terminal to ground the weldmentsafely. In the example of FIG. 1 (while being scalable) the examplesystem uses a three stage power source, comprising power cells 101, 102,and 103. Although the example is shown with three power cells, thesystem is easily scalable increased or decreased, so that amplificationof different potential power development can be implemented. Dependingon the desired use, the number of power cells or batteries can affectthe capacity, weight and size of the system. A three or four power cellsystem has been found to be substantially smaller, lighter and more costeffective than previous generator or other powered systems.

The batteries or power cells are coupled to each other in the followingmanner in one embodiment. The positive post 101P of power cell 101 iscoupled to the negative post 102N of power cell 102 via connector 104.The positive post 102P of power cell 102 is coupled to the negative post103N of power cell 103 via connector 105. The positive post 103P ofpower cell 103 is coupled to the gap 106 along with the negative post101N of power cell 101. The system is scalable as more batteries couldbe added in parallel to add potential energy capacity.

In one embodiment; Connectors 104 and 105 are 3/0 AWG or thickerinterconnects. These interconnects are tuned into the system to providemaximum performance. Each positive post; 101P, 102P, and 103P is tappedvia tuned length weld terminals 107, 108, and 109 so that differentpower levels can be selected and used. The tap 107 is the low power tap,tap 108 is medium power, and tap 109 is high power, scalable rampeddesign. Each respective tap can also be used for remote charging or jumpstarting heavy equipment or vessels at its respective voltage.Internally over sized components and tuned lengths of heavy cablesenhance performance.

The system employs separate high efficiency/frequency chargers 110, 111,and 112 for power cells 101, 102, and 103, respectively. The chargersshould be hooked up in one embodiment via a surge protector to astandard 115 v, 60 Hz, 15 amp plug, allowing for reliable continuouscharging during operation where power is available.

The embodiment of FIG. 1 can induce a tuned pulsed plasma of very highintensity into a very tight zone; hyper-phase energy as informedwaveforms are able to sustain an arc jet under subsurface electrodeplunging. The intense subsurface energetic hyper-phased plasma continuesto weld under a molten compressed atmosphere. The system enables weldingdeeply through base metals to more completely weld a joint inside outpenetrating most completely. Intense plasma heating under magneticforces of EMP/EMF augments impulse a higher energy release forhomogeneous rapid inductive mixing and cleaning action to condition theweldments metal/electrode as well as the weld joint at puddle, whilecompressing out impurities. This welding process is least affected bygravity or wind in any position.

The system also includes a feedback receiver 120 comprising a strand ofparallel toroids 121 and conductive elements which react as channeledstring antennas 122. The feedback receiver is scalable, with at leastone separate end directly connected in parallel at each separatepositive terminal power stage tap acting as an anode element in oneembodiment. The channeled strings are free to pulsate, receive and buildup preponderant electrodynamic energy. Receiving, storing, andtransmitting energy, each strand terminates into an additional torus orantenna element. In the centers 123 of the toroids 121 resides a chamberor cell to contain a desired weldment sample for property scanning.There is also at least one negatively charged energy element directlyconnected in parallel to the last battery's negative terminal, where thebattery is directly connected to the weldments clamp. These positive andnegative elements are free to swing in relation to the field on thesample, creating a feedback environment that is unique for each sample.This drives and safely grounds the weldment as a clean running cathode.Its electrodynamic properties react and vibrate to electromagnetic powerpulsations (EMP/EMF collapses). Preponderant rogue energy is translatedby superposition transformation. Informed energy amplification begins tobuild up and is released as output. The feedback loop stimulatesharmonic resonance and radiation occurs as standing waves build withinthe weldment as biased off the sample by total system influences. Thefeedback receiver 120 interacts and scans the sample which forms afunctional expression of analog properties such as permeability,reluctance and flux density all reacting at will. In this way the devicetranslates and transforms energy into valuable information to beembedded or injected back onto the carrier wave as enriched output. (Inan alternate embodiment imaging technology receiving feedback from thefeedback system at extremely low impedance is applied allowing technicalimaging of the welder performance and structure at will during operationwithout negatively affecting results). The feedback receiver 120enhances welding by injecting intelligent energy back into therespective devices output terminals at stages being used, an establishedreceptive intelligent feedback loop.

Tuning and attenuating the device is automatic as impulses increase overtime as energy and heat builds up. A functional work expression of: baseand sample metallurgies, metallic properties, electrode composition,surface area, mass*natural frequencies of conductivity/devicebandwidth=kinetic energy output at unity. This circuit designmethodology and communications process harnesses and allows one toconduct most efficiently, intelligent high energy welds remotely out inthe field, simply and with ease. The system impulses with highly focusedintense resonant plasma radiation. This blasts away tough impuritieswhile reconstructing metal at its intrinsic metallic structures;according to feedback information from the subatomic quantum stringreactions of the scan by the feedback receiver 120. The device easilyovercomes the magnetic disruptions of weldment joint metal and its airgaps. The plasma reacts favorably at will as it thrusts an audible arceither above or subsurface into the base metal as conducted by the enduser using a selected electrode. In one embodiment the electrode is alow hydrogen content electrode that is usable with DC current. Idealhomogeneous mixing and reconstruction of metal occurs, creating ultrarapid crystalline structures to form, as ultra clean X-Ray quality weldsfreeze up, in any position.

The operation of an embodiment of the system is illustrated in the flowdiagram of FIG. 2. At step 201 a sample of the target metal is placed inthe feedback receiver. At step 202 the sample is scanned so that theproperties of the sample, including metallurgies, metallic properties,electrode composition, surface area, mass* and natural frequencies ofconductivity/device bandwidth=kinetic energy output at unity can bedetermined. At step 203 current is supplied to the welding electrodebased on the results of the scan. At step 204, during welding, there isfeedback to the feedback receiver. At step 205 the feedback receiverautomatically adjusts the welding current based on the feedback and thenreturns the new current to the welding electrode in the feedback loop atstep 203.

The system induces into the weld puddle an energy field stimulatingmetal to behave with high molten cling, freezing rapidly forming tightcrystalline structures. The result is ideal for welding, out ofposition, out in harsh weather.

The ramped three stage power circuit offers soft start properties,reducing burning and spraying of molten metal. It is compact andportable. Power loss is non existent due to its highly conductiveoversized components, conductors, connectors and use of a capacitiveelectrode cable. The system welds with ease the thinnest to thickest ofmetals, sheet metal to one inch plus. The system has high reliability; asolid state design, no moving parts or switches, resulting in near zerofailure rating. Welds are highly repeatable, clean and stackable. Thesystem welds through impurities with minimal surface prep. The devicecan be used anywhere, any time as well as provide auxiliary power fortools, with minimal disturbance inside sensitive areas.

The system runs at a low energy voltage for the first few moments andimpulses so the electrode that can reach deep into the tightest ofspaces without shorting out or blasting through the side coatings. Theelectrode can plunge deeply performing subsurface welds. As compared toMIG welding; there is no cumbersome spool wire feeder or gun componentsto burn up, break down or get in the user's way. The operator can plungethe electrode deep below metal surfaces to weld from the inside out. Theresults are excellent bead appearance, the slag is easily removed,frequently self lifting.

All ferrous and non-ferrous conductive metals can be welded includinghard metals requiring manganese content and cast Iron welds.

In one embodiment, the system of FIG. 1 can be implemented in awatertight container completely epoxy filled and sealed for underwateror severe environmental applications.

It is initially tuned and started up by selecting the appropriate stagedoutput power tap, selected in unison to a properly sized electrode toanswer the magnitude of welding task required. A smaller diameterelectrode (e.g. 3/32″) restricts higher current and a thicker electrode(e.g. ⅛″) allows more current energy to propagate; while increasing to5/32″ An electrode of the system up to ¼″ conducts even higher current.This along with staging one of the output power taps commands both startup current to overall current or overall energy conducted. Colder orheavier metal will conduct higher current energy initially.

As external to internal metallic heating builds up and begins to conductthrough the base metal, the wide spectrum energy output released by thedevice begins to transform dynamically and harmonically to it, as theelectrodynamic conductivities of the metals change impulses buildaccordingly. The plasma at the spark gap weld joint controls andorchestrates high frequency standing waves as rapid EMP fields collapsebuilding up and releasing plasma energy. Harmonic resonance drives theideal energy needed by the feedback loop as is conducted and deliveredby the system. The circuit's conductive nature and output energy isdynamically orchestrated according to weldments, samples, the spark gapat the joint and the systemic intrinsic properties stimulated. Thewelding plasma contains a full spectrum of structural characteristicinformation expressed as work performed superimposed within energeticfrequencies reactions. Focused energy is unfettered by digitalinfluence, the analog information is injected directly on energeticcarrier waves. The plasma temperature build up equates to increasingelectrodynamics intrinsically to the feedback scan of total metallurgiesof system expressed at electrode interface. The overall dynamics andelectrode size selection automatically tune in the amount of actualcurrent energy being conducted, amplified or actually used through theweldments shorted arc circuit. Another benefit is the conditioning andcleaning of the capacitive plates within the batteries power cellsinternally, this equates to a prolonging benefit from the removal ofsulphides off the internal power cell plates under the influence of thehigh frequency regenerative energy pulsations.

1. An apparatus comprising: a power source for a welder comprising aplurality of fuel cells, each fuel cell of the plurality of fuel cellshaving a positive and a negative terminal, the positive terminal of onefuel cell having a tuned connection to the negative terminal of anotherof the fuel cells; a plurality of tuned weld terminals; each tuned weldterminal coupled to the positive terminal of one of the fuel cells andeach tuned weld terminal providing one of a plurality of levels ofpower.
 2. The power source of claim 1 further including a plurality ofchargers, each charger coupled to one of the fuel cells.
 3. The powersource of claim 2 wherein the charges are high frequency chargers. 4.The power source of claim 1 further including a feedback receiver. 5.The power source of claim 4 wherein the feedback receiver comprises astrand of parallel toroids.
 6. A method of tuning a welder comprising:Placing a sample of the material to be welded in a feedback receiver;Scanning the sample; Applying current to a welding electrode; Receivingfeedback to an assembly of toroids; Adjusting the current to the weldingelectrode based on the feedback.